Spindle and suspension system for recreational vehicles

ABSTRACT

Embodiments of the present invention describe a recreational vehicle spindle, including a spindle body having one or more sockets in the spindle body, and an upper attachment mechanism in contact with the spindle body and adapted to attach to a steering component. The spindle also includes a lower attachment mechanism in contact with the spindle body and adapted to attach to a ski or wheel. The one or more sockets are adapted to each receive a ball and stud forming one or more ball joints.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.15/496,815, filed on Apr. 25, 2017, which claims benefit of U.S.Provisional Application No. 62/327,022, filed on Apr. 25, 2016 and whichapplication is incorporated herein by reference. A claim of priority ismade.

BACKGROUND

Snowmobiles are popular land vehicles used as transportation vehicles oras recreational vehicles in cold and snowy conditions. All-terrainvehicles (ATVs) are utilized in both on- and off-road recreational andproductive activities. In general, a snowmobile has a chassis on oraround which the various components of the snowmobile are assembled.Typical snowmobiles include skis for steering, a seat, handlebars, andan endless track for propulsion mounted to a central chassis. The enginedrives a ground-engaging endless track disposed in a longitudinallyextending drive tunnel. The skis serve to facilitate steering as well asto provide flotation of the front of the snowmobile over the snow inwhich it is operated. A handlebar assembly, positioned forward of theseat, is operatively linked to the skis for steering the snowmobile. Theskis may be pivoted to steer the snowmobile, for example, by turning thehandlebars.

The skis support the front of the snowmobile using a suspension systemthat may include suspension or connecting arms mounted to the snowmobilechassis that attach to and support a spindle.

Each spindle may be attached to a ski to form the operative link in thesteering system whereby movement of the handlebars causes rotation ofthe spindles, which causes the skis to turn. Spindles are desired whichreduce production cost and enhance the performance of a snowmobile.

Additionally, all-terrain vehicles (ATV) can utilize one or morespindles. Although this disclosure generally discusses snowmobiles,methods and structures discussed herein in the context of snowmobilesmay also be used with ATVs having wheels or tires, as opposed to skis.

SUMMARY

In some embodiments, a recreational vehicle includes a spindle,including a spindle body having one or more sockets in the spindle body,and an upper attachment mechanism in contact with the spindle body andadapted to attach to a steering component. The spindle also includes alower attachment mechanism in contact with the spindle body and adaptedto attach to a ski or wheel. The one or more sockets are adapted to eachreceive a ball and stud forming one or more ball joints.

Embodiments describe a recreational vehicle suspension system, includingone or more spindle bodies, each body having one or more sockets. Eachspindle body also includes an upper attachment mechanism in contact withthe spindle body and attached to one or more steering components, and alower attachment mechanism in contact with each spindle body andattached to a ski or wheel. The system also includes one or moreconnecting arms in contact with a stud and ball at a distal end andforming a ball joint with each socket of the spindle body. The systemalso includes one or more dampening components in contact with one ormore of the connecting arms and spindle body at a distal end.

Embodiments describe a recreational vehicle, including one or morespindle bodies, each body having one or more sockets. The spindle bodieseach have an upper attachment mechanism in contact with the spindlebody, the upper attachment mechanisms being attached to one or moresteering components. A lower attachment mechanism is in contact witheach spindle body and attached to a ski or wheel. The vehicle alsoincludes one or more connecting arms in contact with a stud and ball ata distal end, forming a ball joint with each socket of the spindle body,and attached to a chassis at the proximal end. One or more dampeningcomponents in contact with one or more of the connecting arms andspindle body at a distal end and attached to the chassis at a proximalend are included. The vehicle also includes an engine mounted on thechassis, a drive track in contact with the chassis, a drive trainoperatively interconnecting the engine with the drive track fordelivering propulsive power to the drive track, and a rear suspensionsystem in contact with at least the chassis and drive track.

Embodiments also include a method of making a recreational vehiclespindle including forming a spindle body, forming one or more sockets inthe spindle body, contacting each of the sockets with a ball, andsecuring the ball within each socket.

BRIEF DESCRIPTION OF DRAWINGS

This written disclosure describes illustrative embodiments that arenon-limiting and non-exhaustive. Reference is made to illustrativeembodiments that are depicted in the figures, in which:

FIGS. 1A-D illustrate perspective view of a spindle, according to anembodiment of this disclosure.

FIG. 1E illustrates a cross-sectional view of a spindle, according to anembodiment of this disclosure.

FIG. 2 illustrates a perspective view of a suspension system, accordingto an embodiment of this disclosure.

FIGS. 3A-E illustrate perspective views of a suspension system in arecreational vehicle, according to an embodiment of this disclosure.

FIG. 4 illustrates a block flow diagram of a method of making a spindle,according to an embodiment of this disclosure.

FIG. 5A illustrates a perspective view of a spindle, according to anembodiment of this disclosure.

FIG. 5B illustrates a cross-sectional view of a spindle, according to anembodiment of this disclosure.

FIG. 6A illustrates an exploded view of a spindle, view of a spindle,according to an embodiment of this disclosure.

FIG. 6B illustrates a perspective view of a spindle, according to anembodiment of this disclosure.

FIGS. 6C-D illustrate cross-sectional views of a spindle, according toan embodiment of this disclosure.

DETAILED DESCRIPTION

Embodiments of the present disclosure describe a spindle, a suspensionsystem including one or more spindles, and recreational vehiclesutilizing a suspension system including one or more spindles. Examplesof recreational vehicles include snowmobiles and all-terrain vehicles(ATVs). The spindle of the present disclosure includes one or moresockets of a ball joint positioned in a spindle body. Such anarrangement reduces the total number of parts in a suspension system orvehicle and lowers the cost of manufacturing. In addition, the spindlereduces the amount of free play in the ball joint, creating a morestable, reliable joint. By removing the attachment step of a ball jointto a spindle, an increased stability and rigidity is created in anyconnecting arm or chassis connection at the ball joint. Further, thedisassembly of the suspension system is simplified as removal of theball from the socket can be accomplished without cutting or breaking ofa weld. Additionally, any connecting arms may be optionally integrateddirectly with the ball joint, further reducing overall part count andincreasing suspension stability. As one side of the front suspensionsystem is generally discussed, it is to be noted that the opposing sideis generally a mirror image.

Referring to FIGS. 1A-E, perspective views of a spindle 100 are shown,according to an embodiment of this disclosure. A spindle body 102includes one or more sockets 106 positioned in the spindle body 102.Each socket 106 is capable of receiving a ball 114 (as shown in FIGS.1C-E) in contact with or integrated with a stud 108. The one or moresockets 106 are adapted to each receive a ball 114 and stud 108 formingone or more ball joints 104. An upper attachment mechanism 112 is incontact with the spindle body 102 and is adapted to attach to a steeringcomponent. A lower attachment mechanism 110 is in contact with thespindle body 102 and is adapted to attach to a ski. If attaching to awheel (such as with an ATV), the attachment mechanism 110 may bepositioned in a central location on the spindle body 102, such asbetween one or more ball joints 104. In some embodiments, the spindlebody 102 is formed from a single casting for forging.

A spindle body 102 can be generally elongated in a vertical plane,substantially perpendicular to the ground. The spindle body 102 may bemanufactured in a variety of shapes, so long as the shape allows thespindle body to structurally connect the ski or wheel of a vehicle andat least one of a steering component 210, a connecting arm 204, 206 anda dampening component 208 (as shown in FIG. 2 ). The spindle body 102can include aesthetic features that can be optionally functional. Suchaesthetic or functional features can include ridges, indentations,protrusions, overall shape, etc. The one or more sockets 106 can bepositioned or formed in an upper portion of the spindle body 102, forexample. The sockets 106 can be centrally located on the spindle body102 or positioned in both an upper portion and lower portion of thespindle body 102. The sockets 106 can be in the same vertical plane oroffset from each other. The spindle body 102 can include one socket 106,two sockets 106, or three or more sockets 106, for example. The socket106 can include inner wall, in contact with a ball 114 and positionedgenerally facing an opposite spindle body 102. The socket 106 caninclude an outer wall, facing away from an opposing spindle body 102.The outer wall of the socket 106 can be flush with an outer wall of thespindle body 102. The outer wall of the socket 106 can optionally beprotruding (e.g., non flush) from the outer wall of the spindle body102. When formed, the outer wall of a socket 106 can be partiallyin-line with the outer wall of the spindle body and partially protrudingfrom the outer wall of spindle body 102.

A cross section view of a spindle body 102 and ball joint 104 is shownin FIG. 1E. The ball 114 may be partially, substantially or whollysurrounded by or in contact with a bearing material 116, such as apolymer. The bearing material 116 can also be a metal or part of thespindle body 102 or socket 106, for example. The bearing material 116can secure the ball 114, reduce friction for the ball 114 or both. Anadjustment mechanism 118 may be positioned in contact with the ball 114.The adjustment mechanism 118 may be a hex key hole, for example. Theball 114 may be held in place at 118 with a tool for tightening ofexternal nuts or other adjustments.

The socket 106 is capable of receiving a ball 114. The ball 114 is incontact with a stud 108. The socket 106, ball 114 and stud 108 form aball joint 104. The ball 114 and stud 108 can be a single unit, such asfrom one-piece manufacturing. The ball 114 and stud 108 can be attached,such as by welding or screwing the stud 108 into the ball 114, forexample. Further, the stud 108 can be attached to or formed with one ormore of a connecting arm 204, 206, a steering component 210, anddampening component 208 (as shown in FIG. 2 ). If formed together orintegrated, the stud 108 may simply refer to some portion of thecomponent in contact with the ball 114. The ball 114 may be pressure fitor friction fit within the socket, so as to allow rotation about thesocket 106 without dislodging the ball 114 from the socket 106. The ball114 can be held in place by forming a portion of the spindle body 102around the ball 114 after contacting with the socket 106, for example.The ball joint 104 formed reduces the free play or unintended movementof the ball 114 within or out of the socket 106. Excessive or increasingfree play contributes to wear and ultimately to failure of the balljoint 104.

The upper attachment mechanism 112 can be positioned at any portion ofthe spindle body 102, so long as the mechanism 112 allows for attachmentto a steering component 210 (as shown in FIG. 2 ). The upper attachmentmechanism 112 can be positioned in the upper portion of the spindle body102, central or mid-portion of the spindle body 102, or in the lowerportion of the spindle body 102. The upper attachment mechanism 112 canbe a bolt hole, threaded protrusion, threaded hole, protrusion forwelding, protrusion for bolting, etc. A protrusion in the direction ofthe rear of the vehicle can create a position or mount for the upperattachment mechanism 112. The upper attachment mechanism 112 can be anymechanical attachment component that facilitates attachment to thesteering component 210, such as a tie rod (as shown in FIG. 2 ).Similarly, the steering component 210 can include a complementary orfacilitating configuration to attach to the spindle body 102.

The lower attachment mechanism 110 can be positioned at any portion ofthe spindle body 102, so long as the mechanism 110 allows for attachmentto a ski 202 (as shown in FIG. 2 ) or wheel of a vehicle. The spindlebody 102 can be positioned and attached to the ski 202 or wheel in avariety of angles and alignments, so long as the attachment is secureenough to translate movement of the skis 202 or wheels in response tomovement of the steering component 210 at the upper attachment mechanism212. Further, the attachment can be pivotal, such as by using a pivotpin to allow the ski 202 to rotate in one or more directions about theattachment 110. The lower attachment mechanism 110 can be positioned inthe central or mid-portion of the spindle body 102 or in the lowerportion of the spindle body 102. The lower attachment mechanism 110 canbe any mechanical attachment component that facilitates attachment tothe ski or wheel. The lower attachment mechanism 110 can be a bolt hole,threaded protrusion, threaded hole, protrusion for welding, protrusionfor bolting, etc. Similarly, the ski or wheel can include acomplementary or facilitating configuration to attach to the spindlebody 102.

Referring to FIG. 2 , a perspective view of a suspension system 200 isshown, according to an embodiment of this disclosure. The suspensionsystem includes one or more spindle bodies 102. Each spindle body 102includes one or more sockets 106 in the spindle body 102 and an upperattachment mechanism 112 attached to one or more steering components210. Each spindle body 102 also includes a lower attachment mechanism110 attached to a ski 202. The suspension system 200 also includes oneor more connecting arms 204, 206, each connecting arm 204, 206 incontact with a stud 108 at a distal end, forming a ball joint 104 witheach socket 106 of the spindle body 102. One or more dampeningcomponents 208 are also included and are in contact with one or more ofthe connecting arms 204, 206 and spindle body 102 at a distal end.

The steering component 210 ultimately connects to and is controlled byhandlebars 304 or handlebar assembly. Various links and linkages (notshown) can connect the steering component 210 in contact with the upperattachment mechanism 112 and handlebars 304. The handlebar assembly,positioned forward of the seat, is operatively linked to the skis by oneor more steering components 210 for steering the vehicle. The skis 202or wheels may be pivoted laterally to steer the vehicle, for example, byturning the handlebars.

The connecting arms 204, 206 can include an upper connecting arm 204 andlower connecting arm 206, example. The connecting arms 204, 206 are incontact with at least one of the spindle body 102 and dampeningcomponent 208. At a distal end of the connecting arms 204, 206, the armsconnect to a stud 108 of the ball joint 104 or some portion of the arms204, 206 function as the stud 108 in the ball joint 104. At a proximalend, the connecting arms 204, 206 attach to or are integrated with thechassis 302. This connection can be pivotal or rotatable, for example.Connecting arms 204, 206 or suspension arms may be of the“trailing/leading arm” variety (not shown), employing an elongatedstructural member attached at its front or distal end to a spindle body102, and pivotally attached at its rear or proximal end to the chassis302 of the vehicle. Suspension arms may also be of the “A-arm” variety(shown), typically employing two A-shaped control arms 204, 206 that arepivotally mounted to the chassis 302 and connect to a spindle body 102at a distal end. Combinations of A-arm and trailing/leading armsuspensions can also be utilized. In an optional embodiment, theconnecting arms 204, 206 or suspension arms are formed with the balljoint 104 as one-piece construction. The arms 204, 206 can be attachedto a stud 108, be attached to a ball 114, or formed with the stud 108 orformed with the ball 114, for example.

One or more dampening components 208 are in contact with at least one ofthe spindle body 102 and/or connecting arms 204, 206. The dampeningcomponents 208 can be shocks, springs, coils, etc. that absorb andconvert energy while operating the vehicle in order to make the ridesmoother and more predictable for the operator or user.

Referring to FIGS. 3A-E, perspective views of a suspension system in arecreational vehicle 300 are shown, according to an embodiment of thisdisclosure. The recreation vehicle includes one or more spindle bodies102. Each spindle body 102 includes one or more sockets 106 in thespindle body 102 and an upper attachment mechanism 112 attached to oneor more steering components 210. Each spindle body 102 also includes alower attachment mechanism 110 attached to a ski 202. The vehicle 300also includes one or more connecting arms 204, 206, each connecting arm204, 206 in contact with a stud 108 and ball 114 at a distal end,forming a ball joint 104 with each socket 106 of the spindle body 102,and attached to a chassis 302 at the proximal end. The chassis 302 inFIGS. 3A-E is generally positioned underneath the shroud or fairing,seat, etc. One or more dampening components 208 are also included andare in contact with one or more of the connecting arms 204, 206 andspindle body 102 at a distal end, and attached to the chassis 302 at aproximal end. The vehicle 300 also includes an engine (not shown),mounted on the chassis 302. A drive track 306 is in contact with thechassis 302 and a drive train 312 is operatively interconnecting theengine with the drive track 306 for delivering propulsive power to thedrive track 306. Also included is a rear suspension system 308, incontact with at least the chassis 302 and drive track 306.

In general, a recreational vehicle, such as a snowmobile, has a centralchassis 302 on or around which the various components of the snowmobileare assembled. Typical snowmobiles include skis 202 for steering, a seat314, handlebars 304, and an endless track (drive track 306) forpropulsion mounted to a central chassis 302. An engine cradle orbulkhead (not shown) is defined by a plurality of front structuralmembers of the chassis. The engine (not shown) drives a ground-engagingendless track (drive track 306) disposed in a longitudinally extendingdrive tunnel formed within the chassis 302. The skis 202 serve tofacilitate steering as well as to provide flotation of the front of thesnowmobile over the snow in which it is operated. The skis 202 aremounted at the front body portion of the chassis.

Drive train 312 facilitates and controls power from the engine to thedrive track 306. The drive train 312 includes a transmission or clutchsystem, for example. A rear suspension system 308 absorbs and convertsenergy to reduce shock impulses from the drive track 306 meeting unevensurfaces.

Referring to FIG. 4 , a block flow diagram of a method 400 of making aspindle is shown, according to an embodiment of this disclosure. Aspindle body is formed 402. On or more sockets are formed 404 in thespindle body. Each of the sockets is contacted 406 with a ball. The ballis then secured 408 within each socket.

In some embodiments, the spindle body 102 is cast, forged, or molded ofa single piece of material, for example aluminum or steel, and thesockets 106 are formed in the spindle body 102. The sockets 106 can beformed in the spindle body 102 during the forming process making thespindle body 102 or they can be subsequently added to the spindle body102. In some embodiments, the sockets 106 define a spherical orsemi-spherical cavity. The spindle body 102 can be hardened via ahardening process. Subsequently, in at least some embodiments, theball(s) 104 is/are placed into socket(s) 106. Thereafter, the bearingmaterial, is molded around the ball(s) 104. In some embodiments, thebearing material is a polymeric material having a desired coefficient offriction. In some embodiments, the polymeric material is Delrin, howeverother thermosets or thermoplastics can be utilized. In some embodiments,the bearing material is injected around the ball 104 between the socket106 and the ball 104.

Forming 402 a spindle body can include utilizing metal fabrication ormetal molding to form the spindle body shape, for example. Metalfabrication includes one or more of laser, plasma, flame and sawcutting, metal machining, computer numeric control (CNC) machining,chiseling, bending, robotic and manual welding. Bending is done byhammering (manual or powered) or via press brakes and similar tools.Assembling (joining of the pieces) is done by welding, binding withadhesives, riveting, threaded fasteners, or additional bending in theform of a crimped seam. Structural steel and sheet metal are often usedas starting materials for fabrication, along with the welding wire,flux, and fasteners that will join the cut pieces. Metal molding, suchas metal injection molding can be utilized. Metal casting and extrusionare further examples of forming 402.

During or after the process of forming 402 the spindle body, one or moresockets are formed 404 in the spindle body. The sockets can be formed404 contiguous and simultaneously with the spindle body, or after someportion or all of the spindle body is formed 402. In addition to, oralternatively to, using steel, the materials used to manufacture thespindle body and sockets include one or more of carbon steel, aluminumalloys, aluminum, steel, magnesium, composite materials, and titaniumalloys.

After forming 404 the sockets, each socket is contacted 406 with a balland then secured 408, to form a ball joint. Contacting 406 can include apressure or friction fit, for example. The ball may be contacted 406with the socket during forming 404 and tabs or protrusions created orformed around the socket and ball to secure 408 the ball within thesocket, for example.

Turning to FIGS. 5A and 5B, an embodiment of the spindle 100 is shown,wherein the spindle body 102 has a wall portion 502, such that the ball114 does not protrude from the spindle body 102 on both sides thereof.The ball 114 can protrude from either or both sides of the spindle body102 by any desired amount so long as the ball 114 is retained. Referringto FIG. 5A, in some embodiments, one or more portions of one or more ofthe studs 108 includes a flat 504 where a wrench (e.g., an open endwrench) can be located such that a nut (not shown) can be tightenedagainst the stud 108. Although the flat 504 is shown in FIG. 5A with asmaller cross sectional area than the adjacent portion of the stud 108,it will be appreciated that the flat 504 can have a larger crosssectional area than the adjacent portion of the stud 108. In someembodiments, the flat 504 is formed from a hexagonal portion, forexample that is integrally formed with the 108.

In some embodiments, the ball 114 is (which can be formed with the stud108 from a single piece of material) is placed within the socket 106using a jig. Thereafter, the bearing material 116 is injected into thesocket 106 around the ball 114. The bearing material 116 then hardenssuch that the ball 114 cannot escape from the socket 106.

With regarding to FIGS. 6A-6D, an embodiment of the spindle 100 isshown. As shown in FIG. 6A, in some embodiments, a ball retainer 602retains the ball 114 therein. In turn, the ball retainer 602 has, insome embodiments, a generally cylindrical outer portion 604 which isseated within a cavity 606. In some embodiments, a pin 608 is pressedinto a portion of the ball retainer 602 and a portion of the spindlebody 102. In some embodiments, the pin 608 prevents movement (e.g.,rotation) of the ball retainer 602 within the cavity 606. In someembodiments, a retaining clip 610 (e.g., spring clip, c-clip, etc.) islocated in a groove 612, as shown in FIGS. 6C and 6D. The retaining clip610 prevents the ball retainer 602 from coming out of the cavity 606(e.g., when a pushing force is applied to the stud 108 in the directionof F₂, as shown in FIG. 6C). Further, as shown in FIG. 6C, in someembodiments, the spindle body 102 has a shoulder 618 which prevents theball retainer 602 from coming out of the cavity 606 (e.g., when apulling force is applied to the stud 108 in the direction F₁).

Other embodiments of the present disclosure are possible. Although thedescription above contains much specificity, these should not beconstrued as limiting the scope of the disclosure, but as merelyproviding illustrations of some of the presently preferred embodimentsof this disclosure. It is also contemplated that various combinations orsub-combinations of the specific features and aspects of the embodimentsmay be made and still fall within the scope of this disclosure. Itshould be understood that various features and aspects of the disclosedembodiments can be combined with or substituted for one another in orderto form various embodiments. Thus, it is intended that the scope of atleast some of the present disclosure should not be limited by theparticular disclosed embodiments described above.

Thus the scope of this disclosure should be determined by the appendedclaims and their legal equivalents. Therefore, it will be appreciatedthat the scope of the present disclosure fully encompasses otherembodiments which may become obvious to those skilled in the art, andthat the scope of the present disclosure is accordingly to be limited bynothing other than the appended claims, in which reference to an elementin the singular is not intended to mean “one and only one” unlessexplicitly so stated, but rather “one or more.” All structural,chemical, and functional equivalents to the elements of theabove-described preferred embodiment that are known to those of ordinaryskill in the art are expressly incorporated herein by reference and areintended to be encompassed by the present claims. Moreover, it is notnecessary for a device or method to address each and every problemsought to be solved by the present disclosure, for it to be encompassedby the present claims. Furthermore, no element, component, or methodstep in the present disclosure is intended to be dedicated to the publicregardless of whether the element, component, or method step isexplicitly recited in the claims.

The foregoing description of various preferred embodiments of thedisclosure have been presented for purposes of illustration anddescription. It is not intended to be exhaustive or to limit thedisclosure to the precise embodiments, and obviously many modificationsand variations are possible in light of the above teaching. The exampleembodiments, as described above, were chosen and described in order tobest explain the principles of the disclosure and its practicalapplication to thereby enable others skilled in the art to best utilizethe disclosure in various embodiments and with various modifications asare suited to the particular use contemplated. It is intended that thescope of the disclosure be defined by the claims appended hereto

Various examples have been described. These and other examples arewithin the scope of the following claims.

What is claimed is:
 1. A method of making a recreational vehiclespindle, comprising: forming a spindle body, the spindle body includingan upper attachment mechanism configured to couple with a steeringcomponent and a lower attachment mechanism configured to couple with aski or a wheel; forming one or more sockets in the spindle body, each ofthe one or more sockets including an inner wall and an outer wall;positioning a ball within each of the sockets; and removably securingthe ball within each socket.
 2. The method of claim 1, wherein forming aspindle body comprises fabricating a spindle body.
 3. The method ofclaim 1, wherein forming a spindle body comprises molding a spindlebody.
 4. The method of claim 1, wherein forming a spindle body andforming one or more sockets is substantially simultaneous.
 5. The methodof claim 1, wherein securing the ball comprises one or more of apressure fit and friction fit.
 6. The method of claim 1, whereinsecuring the ball comprises forming material around the ball aftercontacting the socket with the ball.
 7. The method claim 1, furthercomprising the step of hardening the spindle body via a hardeningprocess.
 8. The method of claim 1, wherein securing the ball within eachsocket comprises positioning the ball such that removal of the ball isaccomplished without breaking a weld.
 9. The method of claim 1, whereinsecuring the ball within each socket comprises positioning the ball suchthat removal of the ball is accomplished without damaging the socket.